Surface mount fluorescent strip light fixture retrofit kit and method

ABSTRACT

A retrofit unit for a fluorescent lighting fixture having a chamber with a ballast and a plurality of downwardly extending lamp holders for enclosing an existing fluorescent strip light fixture, wherein neither the ballast nor the lamp holders of the existing fluorescent lighting fixture need be removed to receive this retrofit unit.

CROSS-REFERENCE TO PRIOR APPLICATION

[0001] This application claims priority to U.S. Provisional PatentApplication Serial No. 60/429,921, filed on Nov. 30, 2002.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] This invention relates to surface mount fluorescent strip lightfixtures, and, more particularly, to a retrofit kit and method ofretrofitting for surface mount fluorescent strip light fixtures.

[0004] 2. Description of Related Art

[0005] Surface mount fluorescent strip light fixtures are installed toprovide general lighting of large indoor spaces. It should be understoodthat the description of the fixtures as ‘surface mount’ type fixtures isintended to distinguish the fixtures from ‘recessed’ type fixtures.Thus, the invention taught herein will apply to all ‘surface mount’ typefluorescent strip light fixtures, including stem and pendant mountedsuspended variations as well as those fixtures mounted directly to aceiling.

[0006] Typically, such strip fixtures include a channel in the form ofan inverted trough, with the channel being attached to the ceiling. Lampholders (sockets) are attached to the channel. A ballast is attachedwithin the channel and wiring attaches the ballast to the lamp holders.Power is supplied to the ballast by wiring brought into the channelthrough the top or end of the channel. A ballast cover is used to closethe open face of the channel so that the ballast and wiring areenclosed. Linear fluorescent lamps are then placed in the lamp holdersfor operation of the fixture. The lamps are left bare and exposed forproviding light to the space. Because of their low cost and utilitarianuse, the surface mount fluorescent strip light fixture is the bestselling light fixture of all time. Thus, as used herein, surface mountfluorescent strip light fixtures shall be understood to include allfixtures having this basic configuration.

[0007] Typical uses include retail stores, such a grocery, drug, anddepartment stores, where the fixtures are commonly mounted in continuousrows. The fixtures are also used in warehouses.

[0008] Since the introduction of the fluorescent lamp at the 1939 WorldFair, fluorescent lighting technology has greatly advanced. Particularlyin response to the energy crisis of the 1970's and the National EnergyPolicy Act of 1992, lamp and ballast manufacturers have developedfluorescent lamp-ballast systems with improved efficiencies. Forexample, electronic ballasts are now capable of more efficient operationthan older technology magnetic ballasts. Additionally, the newer, energysaving fluorescent lamps have special lamp holder and/or ballastrequirements.

[0009] There are a large number of fixtures in the market that useobsolete technology. Consumers desire to reduce their utility costs, andthe newer technology can save 25%, or better, in such costs. However,for existing installations, implementation of the newer technology meanseither replacing the individual fixture components (ballast, lampholders, wiring, and lamps) or replacing the fixtures all together. Bothprocesses are time consuming and labor intensive, requiring 30 minutesor so for each fixture retrofit or replacement. Further, the retrofitprocess requires closing down sections of a store during theconstruction, increasing the impact of the time and effort required toretrofit or replace the old fixtures. Thus, there is a need for aretrofit kit and method for surface mount fluorescent strip lightfixtures that can be installed with a minimum of time and labor.

[0010] Additionally, current retrofit or replacement options for oldfixtures requires disposal of the old ballast, lamp holders, wiring, andlamps, or the entire fixture all together, creating disposal costs andother issues. For instance, many old ballasts contain hazardousmaterials and require disposal treatment as such. Thus, there is afurther need for a retrofit kit and method for surface mount fluorescentstrip light fixtures that minimizes the disposal issues of the retrofitprocess.

BRIEF SUMMARY OF THE INVENTION

[0011] Thus, it is an object of the present invention to provide aretrofit kit and method of retrofitting existing fluorescent strip lightfixtures with a replacement lamp-ballast system.

[0012] It is a further object of the present invention to provide a kitand a method for retrofitting an existing fluorescent strip lightfixture that can be installed with a minimum of time and labor.

[0013] It is even a further object of the present invention to provide aretrofit kit for an existing fluorescent strip light fixture thatminimizes the disposal issues of the retrofit process.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0014]FIG. 1 shows an exploded view of an existing surface mountfluorescent strip light fixture

[0015]FIG. 2 shows a partial perspective view of an existing surfacemount fluorescent strip light fixture and a retrofit kit according tothe present invention, particularly showing a mounting bracket attachedto the existing fixture in alignment with slots in a retrofit channel.

[0016]FIG. 3 shows a perspective view of an existing surface mountfluorescent strip light fixture and the retrofit kit of the presentinvention, particularly showing the retrofit channel hanging on themounting brackets.

[0017]FIG. 4 shows a different perspective view of the arrangement ofFIG. 3, particularly showing the ballast and ballast wiring of theretrofit kit of the present invention. FIG. 4 is show with the secondside wall door removed so that the wiring details are more clearlyvisible.

[0018]FIG. 5 shows a partial perspective view of an existing surfacemount fluorescent strip light fixture and the retrofit kit of thepresent invention, particularly showing the retrofit kit swung intoposition around the existing fixture.

[0019]FIG. 6 is a partial perspective view of the mounting bracket anddoor section outwardly turned flange of FIG. 5.

[0020]FIG. 7 is another view of the components of FIG. 6, with the thumblatch rotated into engagement with the door section flange.

DETAILED DESCRIPTION OF THE INVENTION

[0021] As shown in FIG. 1, an existing surface mount fluorescent striplight fixture 10 has an existing strip channel 12 in the form of aninverted trough, with the existing channel 12 being attached to aceiling 14. As mentioned earlier, surface mount type fluorescent stripfixtures may also be suspended from a ceiling by a stem or other pendanttype suspension system, and it should be understood that the principlestaught herein will apply equally to any surface mount type fluorescentstrip fixture whether it is suspended or mounted directly to a ceiling.The existing channel 12 has a width, w, as shown, which is typicallyaround 4⅛ inches to 4¼ inches. The existing fixture 10 has lamp holders16 which are commonly attached to a saddle piece 18, which is, in turn,suspended between the walls of the existing channel 12. The existingfixture also has a ballast 20, which is contained within the existingchannel 12. Power is supplied to the ballast by power supply leads 22brought into the channel 12, and the ballast 20, in turn, provides powerto the lamp holders 16 by existing lamp holder wiring 24. A ballastcover 26 covers the open face of the existing channel 12 to enclose theballast 20, power wiring 22 and lamp holder wiring 24.

[0022] Preparation of the existing strip fixture 10 for retrofittingwith the retrofit kit and method of the present invention includes:disconnecting power to the existing strip fixture 10; removing theexisting lamps (already removed from the existing fixture shown in FIG.1); and removing the ballast cover 26. The existing lamps and theballast cover 26 will be the only components of the existing stripfixture 10 which require disposal in the retrofit process according tothe instant invention.

[0023] As shown in FIGS. 2-7, the surface mount fluorescent strip lightfixture retrofit kit of the present invention is comprised of twomounting brackets 28 and a retrofit channel 30. The brackets 28 attachto the existing strip channel 12. The retrofit channel 30 hangs from thebrackets 28 and wraps around the remaining components of the existingfixture 10.

[0024] More specifically, as shown in FIG. 2, each mounting bracket 28has a horizontal arm 32, a depending leg 34, and an upturned hooksection 36. The horizontal arm 32 has a first end 38 and a second end 40and a length, 1, which is longer than the width, w, of the existingchannel 12. The depending leg 34 extends downward from the first end 38of the horizontal arm 32 and conforms generally to the shape of thechannel 12. The upturned hook section 36 extends upward and outward fromthe bottom end of the depending leg 34, forming a hook-like structuretherewith. The depending leg 34 contains a fastener hole 42. Preferably,the mounting brackets are made of a heavy gauge (16 gauge or 18 gauge)galvanized steel for strength.

[0025] The retrofit channel 30 has the form of a non-inverted trough,generally, having a first side wall 44, a bottom wall 46, and a secondside wall 48 (shown only partially in FIG. 2). As mentioned earlier, theretrofit channel 30 is proportioned to wrap around the existing fixture10, including the existing channel 12, lamp holders 16, and ballast 20without the need to remove or dispose of those components. The firstside wall 44 of the retrofit channel 30 has an upper end 50 with slots52 formed therein. The slots 52 are each configured to receive theupturned hook section 36 of the mounting brackets 28.

[0026] As shown in FIG. 3, multiple slots are formed along the upper end50 of the first side wall 44.

[0027] Thus, the mounting brackets 28 are installed to the existingchannel 12 by slipping each bracket 28 between the ceiling and theexisting channel 12 so that the upturned hook section 36 lines up with aslot 52 in the retrofit channel 30, as shown in FIG. 2. A template maybe utilized for this alignment, or the installer may simply use a ruleror other measuring device to make the alignment. Should the selectedposition for installation of a bracket 28 be obstructed by a fastenerconnecting the existing channel 12 to the ceiling, or a boss on top ofthe existing channel 12, an alternate location may be easily selected byrelocating the mounting bracket 28 to an alternate location free ofobstructions that lines up with an alternate slot 52. Should theexisting fixture 10 have a suspended mounting arrangement, the mountingbrackets can just be laid on top of the existing channel 12. Should theexisting channel 12 be mounted so close to the ceiling that the mountingbrackets 28 will not fit in the space between the existing channel 12and the ceiling, the bracket may be driven through the space with ahammer. Following positioning of the mounting brackets 28 on top of theexisting channel 12, small pilot holes may be created in the existingchannel 12 in alignment with the fastener holes 42 in the depending legs34 of each mounting bracket 28. Thus, the mounting brackets 28 may befastened to the existing channel 12 with fasteners, such as screws 54through the fastener holes 42 and the pilot holes.

[0028] Upon fastening of the mounting brackets 28 to the existingchannel 12, the retrofit channel 30 may be hung by the slots 52 on theupturned hook sections 36 of the mounting brackets 28, as best shown inFIG. 3.

[0029] As shown in FIG. 4, a retrofit ballast 56 and retrofit lampholders 58 are attached to the retrofit channel 30, and are connected byretrofit lamp holder wiring 60. The design of the retrofit kit andmethod of retrofitting of the present invention enables attachment ofthe retrofit ballast 56 and lamp holders 58, and the connection of theretrofit lamp holder wiring 60 to be performed during the manufacturingof the kit at the factory. Thus, the installer of the kit at theretrofit site does not have to devote time or labor to these tasks.

[0030] As further shown in FIG. 4, the retrofit ballast 56 has powerleads 62 and the retrofit kit has a ground lead 64.

[0031] The next step in installation of the retrofit kit is todisconnect the power supply leads 22 from the existing ballast 20 andconnect the power supply leads 22 to the retrofit ballast power leads62. Additionally, the retrofit kit ground lead 64 should be connected toa through feed ground wire or other ground wire in the existing fixture.

[0032] The mounting bracket upturned hook section 36 and retrofitchannel slots 52 create a hinge that allows the retrofit channel 30 tohang from the mounting brackets 28 in a position such that interiorportion of the retrofit channel 30 is accessible to the installer formaking the described electrical connections, as shown in FIGS. 3 and 4.

[0033] Further facilitating access to the installer for making theelectrical connections, the retrofit channel second side wall 48, bestshown in FIG. 5, can be fabricated as having a door section 66 and alower section 68. In the embodiment shown, the door section 66 is hingedto the lower section 68 through the use of a plurality of T-slots 70along the upper end of the lower section (see FIG. 4) and mating hooks(not shown) formed along the lower edge of the door section 66. Thishinged arrangement of the door section 66 and lower section 68 of thesecond side wall 48 enables the door section 66 to be opened for easieraccess to the interior portion of the retrofit channel 30.

[0034] It should be observed that the door section 66 has been removedfrom the views of FIGS. 2-4 in order to more clearly show the componentdetails of those views. Thus, FIGS. 2-4 show only the lower section 68of the second side wall 48 of the retrofit channel 30. However, itshould be understood that the second side wall 48 of the embodimentshown includes both the lower section 68 and the door section 66.

[0035] Returning now to the view of FIG. 5, it is seen that the topportion of the door section 66 has an outwardly turned flange 72. Thus,after the wiring connections are completed, the retrofit kit may beswung up such that the door section flange 72 seats against theunderside of the mounting bracket second ends 40 (only one mountingbracket 28 shown in FIG. 5).

[0036] As best shown in FIGS. 6 and 7, the underside of each mountingbracket second end 40 has a thumb latch 74 rotatably attached thereto bya rivet 76. Thus, the thumb latch 74 of each mounting bracket second end40 may be rotated out of the way of the door section flange 72 so thatit may seat against the underside of each mounting bracket second end40. Then, the thumb latch 74 of each mounting bracket second end 40 maybe rotated so that it engages the under side of the door section flange72, thereby holding the door section 66, and the retrofit channel 30 inplace, as shown in FIG. 5.

[0037] As further shown in FIG. 5, the retrofit kit may include end caps78 which are configured to close the ends of the retrofitted fluorescentstrip light fixture, or the ends of a row of retrofitted fixtures. Theend caps 78 may be attached to the assembly by any convenient means.

[0038] Continuing with the view of FIG. 5, it is seen that the wraparound arrangement of the retrofit channel 30 and the existing channel12 and existing lamp holders 16 creates a chamber 80 for the retrofitballast 56 and associated wiring (see FIG. 4) without requiring theremoval of the existing ballast 20 (and the associated disposal issues)and associated wiring (see FIG. 1).

[0039] Additionally, as shown in FIG. 5, the wrap around arrangementallows the retrofit channel bottom wall 46 to be wider than the existingchannel 12. Thus, on the embodiment shown, the bottom wall may have aflat portion 82 in the middle and angled portions 84 on either side ofthe flat portion. This allows improved optical performance in thetwo-lamp configuration shown. Additionally, this allows one-lamp andthree-lamp versions of the retrofit kit to be produced by installationof lamp holders and a lamp on the flat portion 82 of the bottom wall 46.

[0040] Returning now to FIGS. 6 and 7, the embodiment of the inventionshown also has a fastener hole 86 located in the thumb latch. Eachmounting bracket second end 40 further has a fastener hole 88 positionedto be in alignment with the thumb latch fastener hole 86 when the thumblatch 74 is rotated into engagement with the door section flange 72.Additionally, fastener holes 90 are located at positions in the doorsection flange 72 corresponding to the slots 52 in the first side wall44 such that the fastener holes 90 will be in alignment with the thumblatch fastener hole 86 and the mounting bracket second end fastener hole88. Thus, a fastener 92, such as a screw, may be fastened through thumblatch fastener hole 86, flange fastener hole 90 and mounting bracketsecond end fastener hole 88 to secure the thumb latch 74 in place and toestablish electrical ground continuity between the respectivecomponents.

[0041] Returning now to FIG. 2, the embodiment of the invention shownalso has a groove 94 positioned along the upper end 50 of the retrofitchannel first side wall 44 such that the slots 52 are located at thebottom of the groove 94. This configuration enables the installer tomore easily position each mounting bracket upturned hook section 36 in afirst side wall slot 52 for hanging the retrofit channel 30 from themounting brackets 28. Additionally, this configuration allows the firstside wall groove 94 to seat against the existing channel 12 in order tomeet code requirements.

[0042] The material of the retrofit channel 30 of the embodiment shownand described is code gauge steel (26 gauge to 16 gauge). However, itshould be noted that the retrofit channel 30 does not require theattachment of conduit thereto, allowing selection of a thinner gaugematerial to meet code requirements and providing for savings in materialcosts. The retrofit channel may be formed on a press break, roll formed,or formed by any other suitable method.

[0043] This description of the invention, including specific dimensionsand materials, shall not be construed as a limitation of any inventionhereafter claimed by the inventors, as it will be readily apparent tothose skilled in the art that design choices may be made withoutdeparting from the spirit or scope of the invention.

What is claimed is: 1 A retrofit unit for a fluorescent lighting fixturecomprising a chamber having a protruding bottom wall for enclosing anexisting fluorescent strip light fixture, wherein said retrofit unitfurther has a ballast in said chamber affixed to said protruding bottomwall and a plurality of downwardly extending lamp holders. 2 Theretrofit unit of claim 1 further comprising two opposing side wallsaffixed to said bottom wall. 3 The retrofit unit of claim 2 furtherhaving a first and second end cap at opposite ends of said retrofit unitand affixed to said two side and bottom walls. 4 The retrofit unit ofclaim 2 wherein said bottom wall has a first and second angled surface.5 The retrofit unit of claim 4 wherein said first and second angledsurfaces have at least one pair of downwardly extending lamp holders. 6The retrofit unit of claim 1 further having power leads extending fromsaid ballast into said chamber. 7 The retrofit unit of claim 1 havinglamp holder wiring leading from said lamp holders to said ballast. 8 Aretrofit unit for a fluorescent lighting fixture comprising a projectingbottom surface and two oppositely attached side walls forming a chamberfor enclosing an existing fluorescent strip light fixture, saidprojecting bottom surface having at least one pair of opposing lampholders extending downwardly. 9 The retrofit unit of claim 8 furthercomprising a ballast inside of said chamber and being affixed to saidprojecting bottom surface of said retrofit unit. 10 The retrofit unit ofclaim 9 further having lamp holder wiring attached to said ballast andto said lamp holders. 11 The retrofit unit of claim 8 wherein saidprojecting bottom surface has a flat surface and a plurality of angledsurfaces extending the length of said bottom surface. 12 The retrofitunit of claim 8 further comprising a opposing pair of end caps beingremovably attached to said bottom surface and two oppositely attachedside walls surrounding said chamber. 13 The retrofit unit of claim 8further having a plurality of mounting brackets removeably attached tosaid side walls. 14 A retrofit unit for a fluorescent lighting fixturecomprising: a protruding bottom wall interposed between a first sidewalland a second sidewall forming an interior chamber having open ends, saidbottom wall having at least one pair of opposing lamp holders extendingoppositely said interior chamber. 15 The retrofit unit of claim 14further comprising a retrofit ballast in said interior chamber andaffixed to said protruding bottom wall. 16 The retrofit unit of claim 14wherein said protruding bottom wall has a plurality of angled surfacesextending the length of said bottom wall. 17 The retrofit unit of claim14 further comprising end caps, said end caps being removably attachedto said retrofit unit at said open ends of said interior chamber. 18 Theretrofit unit of claim 14 further comprising a plurality of mountingbrackets, said plurality of mounting brackets removeably attached tosaid first and second sidewall opposite said bottom wall. 19 Theretrofit unit of claim 18 wherein each of said mounting brackets has afirst end, a second end, and a horizontal arm extending between saidfirst and second end, said first end having a depending leg extendingdownward from said horizontal arm, said depending leg having an upturnedhook that cooperates with a plurality of slots opposite said bottom wallin said first sidewall. 20 The retrofit unit of claim 15 furthercomprising lamp holder wiring attached to said lamp holders and saidballast. 21 The retrofit unit of claim 15 further comprising ballastpower leads extending from said ballast into said interior chamber. 22 Aretrofit unit for a fluorescent lighting fixture comprising: a retrofitunit forming an elongated retrofit channel having a protruding bottomside; a ballast attached to an interior surface of said protrudingbottom side; at least one pair of opposing lamp holders attached to anexterior surface of said retrofit channel; and a plurality of mountingbrackets removably attached to said retrofit channel opposite saidbottom side. 23 A retrofit assembly for a fluorescent lighting fixturecomprising: an existing fluorescent lighting fixture having an existingballast and existing plurality of lamp holders; a retrofit unit formingan elongated retrofit channel surrounding said existing fluorescentlight fixture; a ballast attached to an interior surface of saidretrofit channel; at least one pair of opposing lamp holders attached toan exterior surface of said retrofit unit; and a plurality of mountingbrackets removably attached to two opposing sides of said retrofit unit.24 A method for retrofitting a fluorescent lighting fixture, comprisingthe steps of: disconnecting power to an existing fluorescent lightingfixture; removing lamps and ballast cover from said existing lightingfixture; placing a plurality of mounting brackets on top of saidexisting lighting fixture; hanging a retrofit unit on said plurality ofmounting brackets, wherein said plurality of mounting brackets cooperatewith slots in a side of said retrofit unit; connecting power and groundleads to said retrofit unit; swinging up said retrofit unit adjacentsaid plurality of mounting brackets; and attaching said retrofit unit tosaid plurality of mounting brackets. 25 An apparatus for retrofitting afluorescent lighting fixture comprising: a retrofit channel formingmember having a protruding bottom wall and pair of opposing side walls;at least one pair of opposing lamp holders affixed to said bottom wall;a means for supplying power to said opposing lamp holders; and a meansfor affixing said retrofit channel to an existing fluorescent lightingfixture. 26 The retrofitting apparatus of claim 25 wherein said meansfor supplying power comprises a ballast affixed to said protrudingbottom wall, ballast power leads, and lamp holder wiring. 27 Theretrofitting apparatus of claim 25 wherein said means for affixing saidretrofit channel comprises a plurality of mounting brackets beingremovebly affixed to said pair of opposing side walls opposite saidbottom wall.